Controls KS-105 User manual

Product Manual
Part Number: KS-105
Revision: 1.1
______________________________________________________________________________________________________________________________________
Copyright Controls, Inc.
P.O. Box 368 • Sharon Center, OH 44274
Phone [phone] • Fax [phone] • www.controlsinc.com

1
TABLE OF CONTENTS
PANEL OVERVIEW ................................................................................................2
PANEL COMPONENTS .........................................................................................3
INSTALLATION .....................................................................................................4
PRODUCT IDENTIFICATION ................................................................................5
PANEL OPERATION ..............................................................................................6
LAMP OPERATION ...............................................................................................7
ENGINE HARNESS CONNECTOR .........................................................................8
INTERNAL CONNECTOR ......................................................................................9
CIRCUIT OPERATION .........................................................................................10
PANEL DIMENSIONS..........................................................................................12
SPECIFICATION...................................................................................................13
REPLACEMENT COMPONENTS .........................................................................14

2
PANEL OVERVIEW
Integrated Panel & Bracket
Compact One Pieces Design
Powder Coated Steel
Welded Corners for Support and Minimized
Vibration
Mounts Directly into Engine Mounting Foot
Potted Electronics Module
Operating Range 5.5 VDC to 36 VDC
Temperature Range -40°C (-40°F) to 80°C (176°F)
Potting Provides Water Tightness and Superior
Vibration/Shock Protection
5 High Intensity LED Lamps
Water Tight, Tough and Long Lasting
Oil Pressure, Coolant Temperature, Alternator
Charge, Glow Plug, Altitude Compensation
Key Switch
Water Tight, Rated IP67
Water Tight Plug and Play Connector
Dedicated Pre-Heat Position
Hour Meter
Potting Provides Water Tightness and Superior
Vibration/Shock Protection
Connector
10 Inch Pigtail to Delphi 15422562 Connector
Pre-Heat / Glow Plug
4 Seconds or 15 Seconds (Selectable)
Dedicated Pre Heat position on Key Switch
Glow Plug Energized During Cranking
Crank Protection
Starter will not engage during engine running
Over crank protection (over-crank >30 seconds)
Engine Safety Shutdowns
Low Oil Pressure
High Engine Temperature
Shutdown bypass is 10 seconds during engine start
.
Provisions for Auto Start
The panel is designed so that it can be upgraded
to an auto start version in the same product
platform.

3
Mounting
Screws
Mounting
Screws
Engine
Harness
Connector
Hour
Meter
High
Intensity
LED
Indication
Lamps
Mounting
Bolts &
Spacers
Key
Switch
Powder
Coated
Steel Case
INSIDE
KS Series
Microprocessor
Platform
PANEL COMPONENTS

4
Mounting
Bolts and
Spacers
INSTALLATION
The KS-105 installs into the engine mounting bracket via four bolts, spacers and a plug and
play connector.
Control Panel Mounted Inside
Bracket
Installation Procedure
1) Turn Power Off
2) Insert unit into bracket
3) Install four screws
4) Plug in connector

5
PRODUCT IDENTIFICATION
Every panel has a product label that provides the part number and individual serial number
for identification.

6
PANEL OPERATION
The KS-105 provides manual start and stop with a key switch. The key switch is an
independently water tight component with a simple plug and play connector. The
individual keys are provided with a rubber boot to protect the key and key switch.
Key Switch
The key switch provides the following operational positions
OFF Position
Run Position
Crank Position
Pre-Heat
Engine Pre-Heat
When the key is turned to the PRE-HEAT position, the KS-105 energizes the pre-heat
signal (connector pin W5) for a 4 second period. If engine connector pin W1 (pre-heat
interval select) is grounded, the pre-heat period is 10 seconds. During pre-heat
operation, the yellow GLOW PLUG lamp illuminates.
Engine Start
When the key is turned to the CRANK position, the KS-105 energizes the crank signal
(connector pin W3), the fuel pull signal (connector pin W6) and the fuel hold signal
(connector pin W7) to initiate the engine crank and start process.
Engine Start Protections
1) Over Crank Protection –Over crank protection is provided by the KS-105.
Cranking is discontinued after holding the key in the CRANK position for 30
seconds.
2) Starter Re-Engage Protection –While the engine is running, the KS-105
disables the crank signal to prevent the starter engagement during
running.
Engine Stop
Turn the key switch to the OFF position to turn the engine off.

7
LAMP OPERATION
The KS-105 comes with five high intensity LEDs lamps.
Oil Pressure Lamp
Oil pressure lamp turns ON when the oil
pressure switch is “closed” indicating a
low oil pressure condition (after initial 10
second bypass period on engine start).
Hour Meter
Displays engine run hours.
Coolant Temperature Lamp
Coolant temperature lamp turns ON
when the engine temperature switch is
“closed” indicating a high engine
temperature condition.
Alternator Charge Lamp
Alternator charge lamp turns ON when
alternator excite signal is received from
the alternator.
Glow Plug Lamp
The glow plug lamp turns “ON” when
the glow plug signal is being sent from
the KS-105. The glow plug signal is
initiated when the key is in the “PRE-
HEAT” position or the “CRANK”
position. The pre-heat period is either
4 or 10 seconds depending on the
pre-heat interval select circuit being
grounded or not.
Altitude Compensation Lamp
The altitude compensation lamp turns
ON when the altitude compensation
signal is received from the altitude
compensation module mounted on
the engine.

8
ENGINE HARNESS CONNECTOR
The KS-105 provides a plug and play connector to the Yanmar engine harness.
Panel Ratings:
The KS Panel is rated at 3 Amp Maximum
Fuel Hold: 2.1A max @ 12v sourcing
Crank and Preheat: 500mA max (Close to Ground)
Pre-Heat Interval Select
A loose wire with a bullet connector provides connectivity for the
Pre-Heat Interval Selection.

9
INTERNAL CONNECTOR
The KS-105 provides a plug and play connector to the KS Series microprocessor
electronics module.
794824-1 Connector
1-1586359-6 Wire Seal
1-1586362-6 Connector Seal
794831-1 Terminals

10
CIRCUIT OPERATION (for 12VDC battery system)
A detailed description of each KS-105 circuit is provided to address both operational
and troubleshooting questions. Controls Inc technical assistance is also available by
calling 330.239.4345 and asking to speak with a technician. (Please have the product part
number and serial number available.)
#
Description
Operation
Loose
Wire to
W1
Pre-Heat Interval Select
Two options for pre-heat timer based on this input being open or
closed to ground:
Not Ground = 4 second Pre-Heat Signal
Ground = 10 second Pre-Heat Signal
Hour
Meter to
W2
Hour Meter Signal
Solid state close to ground signal based on engine running condition
(200mA max)
P to W3
Crank Signal
Close to ground output when key is in the “CRANK” position
(This is a close to ground signal circuit to energize the crank relay with a 500mA
max. This circuit is disabled while engine is running.)
C to W4
Alternator Charge Lamp
12VDC signal from the alternator used to turn the alternator excite
lamp ON
H to W5
Pre-Heat Signal
Close to ground signal when key is in the “PRE-HEAT” or “CRANK”
position
(This is a close to ground signal circuit to energize the pre-heat relay with a
500mA max)
F to W6
Fuel Pull Signal
12VDC signal to fuel pull circuit when key is in the “CRANK” position
for a max of 5 seconds
(This is a 12VDC signal circuit to energize the fuel pull relay with a 2.1A max)
D to W7
Fuel Hold Signal
12VDC signal to fuel hold circuit when key is in the “CRANK” or “RUN”
position
(This is a 12VDC signal circuit to energize the fuel hold relay with a 2.1A max)
G to W8
Battery Negative (B-)
Battery negative supply from B- terminal on battery
K to W9
Speed Signal
Input to KS-105 from engine alternator tach output. The speed signal
is used to indicate the engine is running and is required for the panel
to operate the engine properly.
E to W10
High Altitude Signal
12VDC input to KS-105 from the engine altitude module
M to W12
High Temp Switch
Normally open input
Open = Temperature below Yanmar switch specification
Close to Ground = High temperature alarm (engine shutdown)

11
L to W13
Low Pressure Switch
Normally closed input
Open = Oil pressure within Yanmar switch specification
Close to Ground = Low oil pressure alarm (engine shutdown)
(There is a 10 second oil pressure shutdown bypass period during engine
start to allow pressure to build and open the low-pressure switch)
Key
Switch
Pos 2 to
W14
Crank Position Input
KS-105 key switch position detect
Key
Switch
Pos 3 to
W15
Pre-Heat Position Input
KS-105 pre-heat key switch position detect
A to W16
Battery Positive (B+)
12VDC power supply for panel from B+ terminal on battery

12
DIMENSIONS

13
SPECIFICATIONS

14
REPLACEMENT COMPONENTS
Replacement components are listed below. Please contact Controls Inc for details.